Method and system for separating a feed stream with a feed stream distribution mechanism

ABSTRACT

The present disclosure provides a distillation tower for separating a feed stream. The distillation tower includes a controlled freeze zone section having a controlled freeze zone upper section and a controlled freeze zone lower section below the controlled freeze zone upper section. The controlled freeze zone section includes: (a) a spray assembly in the controlled freeze zone upper section; (b) a melt tray assembly in the controlled freeze zone lower section; (c) a feed stream distribution mechanism between the spray assembly and the melt tray assembly. The feed stream distribution mechanism is constructed and arranged to uniformly distribute the feed stream in the controlled freeze zone section.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefit of both U.S. Provisional patent application No. 61/912,975 filed Dec. 6, 2013 entitled METHOD AND SYSTEM FOR SEPARATING A FEED STREAM WITH A FEED STREAM DISTRIBUTION MECHANISM, the entirety of which is incorporated by reference herein.

This application is related to but does not claim priority to U.S. Provisional patent application numbers: 61/912,957 filed on Dec. 6, 2013 entitled METHOD AND DEVICE FOR SEPARATING HYDROCARBONS AND CONTAMINANTS WITH A SPRAY ASSEMBLY; 62/044,770 filed on Sep. 2, 2014 entitled METHOD AND DEVICE FOR SEPARATING HYDROCARBONS AND CONTAMINANTS WITH A SPRAY ASSEMBLY; 61/912,959 filed on Dec. 6, 2013 entitled METHOD AND SYSTEM OF MAINTAING A LIQUID LEVEL IN A DISTILLATION TOWER; 61/912,964 filed on Dec. 6, 2013 entitled METHOD AND DEVICE FOR SEPARATING A FEED STREAM USING RADIATION DETECTORS; 61/912,970 filed on Dec. 6, 2013 entitled METHOD AND SYSTEM OF DEHYDRATING A FEED STREAM PROCESSED IN A DISTILLATION TOWER; 61/912,978 filed on Dec. 6, 2013 entitled METHOD AND SYSTEM FOR PREVENTING ACCUMULATION OF SOLIDS IN A DISTILLATION TOWER; 61/912,983 filed on Dec. 6, 2013 entitled METHOD OF REMOVING SOLDS BY MODIFYING A LIQUID LEVEL IN A DISTILLATION TOWER; 61/912,984 filed on Dec. 6, 2013 entitled METHOD AND SYSTEM OF MODIFYING A LIQUID LEVEL DURING START-UP OPERATIONS; 61/912,986 filed on Dec. 6, 2013 entitled METHOD AND DEVICE FOR SEPARATING HYDROCARBONS AND CONTAMINANTS WITH A HEATING MECHANISM TO DESTABILIZE AND/OR PREVENT ADHESION OF SOLIDS; 61/912,987 filed on Dec. 6, 2013 entitled METHOD AND DEVICE FOR SEPARATING HYDROCARBONS AND CONTAMINANTS WITH A SURFACE TREATMENT MECHANISM.

BACKGROUND

Fields of Disclosure

The disclosure relates generally to the field of fluid separation. More specifically, the disclosure relates to the cryogenic separation of contaminants, such as acid gas, from a hydrocarbon.

Description of Related Art

This section is intended to introduce various aspects of the art, which may be associated with the present disclosure. This discussion is intended to provide a framework to facilitate a better understanding of particular aspects of the present disclosure. Accordingly, it should be understood that this section should be read in this light, and not necessarily as admissions of prior art.

The production of natural gas hydrocarbons, such as methane and ethane, from a reservoir oftentimes carries with it the incidental production of non-hydrocarbon gases. Such gases include contaminants, such as at least one of carbon dioxide (“CO₂”), hydrogen sulfide (“H₂S”), carbonyl sulfide, carbon disulfide and various mercaptans. When a feed stream being produced from a reservoir includes these contaminants mixed with hydrocarbons, the stream is oftentimes referred to as “sour gas.”

Many natural gas reservoirs have relatively low percentages of hydrocarbons and relatively high percentages of contaminants. Contaminants may act as a diluent and lower the heat content of hydrocarbons. Some contaminants, like sulfur-bearing compounds, are noxious and may even be lethal. Additionally, in the presence of water some contaminants can become quite corrosive.

It is desirable to remove contaminants from a stream containing hydrocarbons to produce sweet and concentrated hydrocarbons. Specifications for pipeline quality natural gas typically call for a maximum of 2-4% CO₂ and ¼ grain H₂S per 100 scf (4 ppmv) or 5 mg/Nm3 H₂S. Specifications for lower temperature processes such as natural gas liquefaction plants or nitrogen rejection units typically require less than 50 ppm CO₂.

The separation of contaminants from hydrocarbons is difficult and consequently significant work has been applied to the development of hydrocarbon/contaminant separation methods. These methods can be placed into three general classes: absorption by solvents (physical, chemical and hybrids), adsorption by solids, and distillation.

Separation by distillation of some mixtures can be relatively simple and, as such, is widely used in the natural gas industry. However, distillation of mixtures of natural gas hydrocarbons, primarily methane, and one of the most common contaminants in natural gas, carbon dioxide, can present significant difficulties. Conventional distillation principles and conventional distillation equipment are predicated on the presence of only vapor and liquid phases throughout the distillation tower. The separation of CO₂ from methane by distillation involves temperature and pressure conditions that result in solidification of CO₂ if a pipeline or better quality hydrocarbon product is desired. The required temperatures are cold temperatures typically referred to as cryogenic temperatures.

Certain cryogenic distillations can overcome the above mentioned difficulties. These cryogenic distillations provide the appropriate mechanism to handle the formation and subsequent melting of solids during the separation of solid-forming contaminants from hydrocarbons. The formation of solid contaminants in equilibrium with vapor-liquid mixtures of hydrocarbons and contaminants at particular conditions of temperature and pressure takes place in a controlled freeze zone section. A lower section may also help separate the contaminants from the hydrocarbons but the lower section is operated at a temperature and pressure that does not form solid.

Often times the feed stream separated in a distillation tower having a controlled freeze zone section is first introduced into the distillation tower via the lower section regardless of the amount of CO₂ in the feed stream.

Disadvantages may arise when the feed stream is first introduced into the lower section regardless of the amount of CO₂ in the feed stream. Disadvantages may include a distillation tower that is not optimally sized. Disadvantages may include a distillation tower that does not use energy efficiently. These disadvantages may arise because the distillation tower may be using more energy and/or space than necessary to process a feed stream when the amount of CO₂ in the feed stream is not properly considered before introducing the feed stream into the distillation tower.

Disadvantages may arise because solids may adhere to an internal (e.g. the controlled freeze zone wall) of the controlled freeze zone section rather than falling to the bottom of the controlled freeze zone section. The adherence, if uncontrolled, can interfere with the proper operation of the controlled freeze zone section and the effective separation of methane from contaminants.

A need exists for improved technology for separating a feed stream that optimally matches where the feed stream should enter the distillation tower based on the concentrations of components in the feed stream so as to optimize energy efficiency and/or the size of the distillation tower.

SUMMARY

The present disclosure provides a device and method for separating contaminants from hydrocarbons, among other things.

A distillation tower for separating a feed stream may comprise a controlled freeze zone section having a controlled freeze zone upper section and a controlled freeze zone lower section below the controlled freeze zone upper section, wherein the controlled freeze zone section is constructed and arranged to form a solid from a feed stream and the controlled freeze zone section comprises: (a) a spray assembly in the controlled freeze zone upper section; (b) a melt tray assembly in the controlled freeze zone lower section; (c) a feed stream distribution mechanism between the spray assembly and the melt tray assembly. The feed stream distribution mechanism may be constructed and arranged to uniformly distribute the feed stream in the controlled freeze zone section.

A method of separating a feed stream in a distillation tower may comprise directly introducing a feed stream into a distillation tower via a controlled freeze zone section of the distillation tower; operating the controlled freeze zone section at a temperature and pressure at which the feed stream forms a solid in the controlled freeze zone section; uniformly distributing the feed stream introduced into the controlled freeze zone section with a feed stream distribution mechanism that is below a spray assembly of the controlled freeze zone section; and forming a solid from the feed stream in the controlled freeze zone section.

A method of producing hydrocarbons in a distillation tower may comprise directly introducing a feed stream into a distillation tower via a controlled freeze zone section of the distillation tower; operating the controlled freeze zone section at a temperature and pressure at which the feed stream forms a solid in the controlled freeze zone section; uniformly distributing the feed stream introduced into the controlled freeze zone section with a feed stream distribution mechanism that is below a spray assembly of the controlled freeze zone section; and producing a hydrocarbon from the feed stream.

The foregoing has broadly outlined the features of the present disclosure in order that the detailed description that follows may be better understood. Additional features will also be described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the disclosure will become apparent from the following description, appending claims and the accompanying drawings, which are briefly described below.

FIG. 1 is a schematic diagram of a tower with sections within a single vessel.

FIG. 2 is a schematic diagram of a tower with sections within multiple vessels.

FIG. 3 is a schematic diagram of a tower with sections within a single vessel.

FIG. 4 is a schematic diagram of a tower with sections within multiple vessels.

FIG. 5 is a side view of a middle controlled freeze zone section of a distillation tower.

FIG. 6 is a cross-section of a feed stream distribution mechanism of FIG. 3 along line 4-4.

FIG. 7 is a cross-section of a feed stream distribution mechanism of FIG. 3 along line 5-5.

FIG. 8 is a cross-section of a feed stream distribution mechanism of FIG. 3 along line 6-6.

FIG. 9 is a flowchart of a method within the scope of the present disclosure.

It should be noted that the figures are merely examples and no limitations on the scope of the present disclosure are intended thereby. Further, the figures are generally not drawn to scale, but are drafted for purposes of convenience and clarity in illustrating various aspects of the disclosure.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the features illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications, and any further applications of the principles of the disclosure as described herein are contemplated as would normally occur to one skilled in the art to which the disclosure relates. It will be apparent to those skilled in the relevant art that some features that are not relevant to the present disclosure may not be shown in the drawings for the sake of clarity.

As referenced in this application, the terms “stream,” “gas stream,” “vapor stream,” and “liquid stream” refer to different stages of a feed stream as the feed stream is processed in a distillation tower that separates methane, the primary hydrocarbon in natural gas, from contaminants. Although the phrases “gas stream,” “vapor stream,” and “liquid stream,” refer to situations where a gas, vapor, and liquid is mainly present in the stream, respectively, there may be other phases also present within the stream. For example, a gas may also be present in a “liquid stream.” In some instances, the terms “gas stream” and “vapor stream” may be used interchangeably.

The disclosure relates to a system and method for separating a feed stream in a distillation tower. The system and method helps optimally match where the feed stream should enter the distillation tower based on the concentrations of components in the feed stream so as to improve energy efficiency and/or optimally size the distillation tower. The system and method may also help prevent the undesired accumulation of solids in the controlled freeze zone section of the distillation tower. FIGS. 1-9 of the disclosure display various aspects of the system and method.

The system and method may separate a feed stream having methane and contaminants. The system may comprise a distillation tower 104, 204 (FIGS. 1-2). The distillation tower 104, 204 may separate the contaminants from the methane.

The distillation tower 104, 204 may be separated into three functional sections: a lower section 106, a middle controlled freeze zone section 108 and an upper section 110. The distillation tower 104, 204 may incorporate three functional sections when the upper section 110 is needed and/or desired.

The distillation tower 104, 204 may incorporate only two functional sections when the upper section 110 is not needed and/or desired. When the distillation tower does not include an upper section 110, a portion of vapor leaving the middle controlled freeze zone section 108 may be condensed in a condenser 122 and returned as a liquid stream via a spray assembly 129. Moreover, lines 18 and 20 may be eliminated, elements 124 and 126 may be one and the same, and elements 150 and 128 may be one and the same. The stream in line 14, now taking the vapors leaving the middle controlled freeze section 108, directs these vapors to the condenser 122.

The lower section 106 may also be referred to as a stripper section. The middle controlled freeze zone section 108 may also be referred to as a controlled freeze zone section. The upper section 110 may also be referred to as a rectifier section.

The sections of the distillation tower 104 may be housed within a single vessel (FIGS. 1 and 3). For example, the lower section 106, the middle controlled freeze zone section 108, and the upper section 110 may be housed within a single vessel 164.

The sections of the distillation tower 204 may be housed within a plurality of vessels to form a split-tower configuration (FIGS. 2 and 4). Each of the vessels may be separate from the other vessels. Piping and/or another suitable mechanism may connect one vessel to another vessel. In this instance, the lower section 106, middle controlled freeze zone section 108 and upper section 110 may be housed within two or more vessels. For example, as shown in FIGS. 2 and 4, the upper section 110 may be housed within a single vessel 254 and the lower and middle controlled freeze zone sections 106, 108 may be housed within a single vessel 264. When this is the case, a liquid stream exiting the upper section 110, may exit through a liquid outlet bottom 260. The liquid outlet bottom 260 is at the bottom of the upper section 110. Although not shown, each of the sections may be housed within its own separate vessel, or one or more section may be housed within separate vessels, or the upper and middle controlled freeze zone sections may be housed within a single vessel and the lower section may be housed within a single vessel, etc. When sections of the distillation tower are housed within vessels, the vessels may be side-by-side along a horizontal line and/or above each other along a vertical line.

The split-tower configuration may be beneficial in situations where the height of the distillation tower, motion considerations, and/or transportation issues, such as for remote locations, need to be considered. This split-tower configuration allows for the independent operation of one or more sections. For example, when the upper section is housed within a single vessel and the lower and middle controlled freeze zone sections are housed within a single vessel, independent generation of reflux liquids using a substantially contaminant-free, largely hydrocarbon stream from a packed gas pipeline or an adjacent hydrocarbon line, may occur in the upper section. And the reflux may be used to cool the upper section, establish an appropriate temperature profile in the upper section, and/or build up liquid inventory at the bottom of the upper section to serve as an initial source of spray liquids for the middle controlled freeze zone section. Moreover, the middle controlled freeze zone and lower sections may be independently prepared by chilling the feed stream, feeding it to the optimal location be that in the lower section or in the middle controlled freeze zone section, generating liquids for the lower and the middle controlled freeze zone sections, and disposing the vapors off the middle controlled freeze zone section while they are off specification with too high a contaminant content. Also, liquid from the upper section may be intermittently or continuously sprayed, building up liquid level in the bottom of the middle controlled freeze zone section and bringing the contaminant content in the middle controlled freeze zone section down and near steady state level so that the two vessels may be connected to send the vapor stream from the middle controlled freeze zone section to the upper section, continuously spraying liquid from the bottom of the upper section into the middle controlled freeze zone section and stabilizing operations into steady state conditions. The split tower configuration may utilize a sump of the upper section as a liquid receiver for the pump 128, therefore obviating the need for a liquid receiver 126 in FIGS. 1 and 3.

The system may also include a heat exchanger 100 (FIGS. 1-4). The feed stream 10 may enter the heat exchanger 100 before entering the distillation tower 104, 204. The feed stream 10 may be cooled within the heat exchanger 100. The heat exchanger 100 helps drop the temperature of the feed stream 10 to a level suitable for introduction into the distillation tower 104, 204.

The system may include an expander device 102 (FIGS. 1-4). The feed stream 10 may enter the expander device 102 before entering the distillation tower 104, 204. The feed stream 10 may be expanded in the expander device 102 after exiting the heat exchanger 100. The expander device 102 helps drop the temperature of the feed stream 10 to a level suitable for introduction into the distillation tower 104, 204. The expander device 102 may be any suitable device, such as a valve. If the expander device 102 is a valve, the valve may be any suitable valve that may aid in cooling the feed stream 10 before it enters the distillation tower 104, 204. For example, the valve 102 may comprise a Joule-Thompson (J-T) valve.

The system may include a feed separator 103 (FIGS. 3-4). The feed stream may enter the feed separator before entering the distillation tower 104, 204. The feed separator may separate a feed stream having a mixed liquid and vapor stream into a liquid stream and a vapor stream. Lines 12 may extend from the feed separator to the distillation tower 104, 204. One of the lines 12 may receive the vapor stream from the feed separator. Another one of the lines 12 may receive the liquid stream from the feed separator. Each of the lines 12 may extend to the same and/or different sections (i.e. middle controlled freeze zone, and lower sections) of the distillation tower 104, 204. The expander device 102 may or may not be downstream of the feed separator 103. The expander device 102 may comprise a plurality of expander devices 102 such that each line 12 has an expander device 102.

The system may include a dehydration unit 261 (FIGS. 1-4). The feed stream 10 may enter the dehydration unit 261 before entering the distillation tower 104, 204. The feed stream 10 enters the dehydration unit 261 before entering the heat exchanger 100 and/or the expander device 102. The dehydration unit 261 removes water from the feed stream 10 to prevent water from later presenting a problem in the heat exchanger 100, expander device 102, feed separator 103, or distillation tower 104, 204. The water can present a problem by forming a separate water phase (i.e., ice and/or hydrate) that plugs lines, equipment or negatively affects the distillation process. The dehydration unit 261 dehydrates the feed stream to a dew point sufficiently low to ensure a separate water phase does not form at any point downstream during the rest of the process. The dehydration unit may be any suitable dehydration mechanism, such as a molecular sieve or a glycol dehydration unit.

The system may include a filtering unit (not shown). The feed stream 10 may enter the filtering unit before entering the distillation tower 104, 204. The filtering unit may remove undesirable contaminants from the feed stream before the feed stream enters the distillation tower 104, 204. Depending on what contaminants are to be removed, the filtering unit may be before or after the dehydration unit 261 and/or before or after the heat exchanger 100.

The system may include lines 12. Each of the lines may be referred to as an inlet channel 12. The feed stream is introduced into the distillation tower 104, 204 through one of the lines 12. One or more lines 12 may extend to the lower section 106 or the middle controlled freeze zone section 108 of the distillation tower 104, 204 to another of the lines 12. For example, the line 12 may extend to the lower section 106 such that the feed stream 10 may enter the lower section 106 of the distillation tower 104, 204 (FIGS. 1-4). Each line 12 may directly or indirectly extend to the lower section 106 or the middle controlled freeze zone section 108. Each line 12 may extend to an outer surface of the distillation tower 104, 204 before entering the distillation tower.

If the system includes the feed separator 103 (FIGS. 3-4), the line 12 may comprise a plurality of lines 12. Each line may be the same line as one of the lines that extends from the feed separator to a specific portion of the distillation tower 104, 204.

Before entering the distillation tower 104, 204, a sample of the feed stream 10 may enter an analyzer (not shown). The sample of the feed stream 10 may be a small sample of the feed stream 10. The feed stream 10 may comprise feed from multiple feed sources or feed from a single feed source. Each feed source may comprise, for example, a separate reservoir, one or more wellbores within one or more reservoirs, etc. The analyzer may determine the percentage of CO₂ in the sample of the feed stream 10 and, therefore, the content of CO₂ in the feed stream 10. The analyzer may connect to multiple lines 12 so that the feed stream 10 can be sent to one or more sections 106, 108 of the distillation tower 104, 204 after the sample of the feed stream 10 exits the analyzer. If the analyze determines that the percentage of CO₂ is greater than about 20% or greater than 20%, the analyzer may direct the feed stream to the line 12 extending from the lower section 106. If the analyzer determines that the percentage of CO₂ is less than about 20% or less than 20%, the analyzer may direct the feed stream to the line 12 extending from the middle controlled freeze zone section 108. The analyzer may be any suitable analyzer. For example, the analyzer may be a gas chromatograph or an IR analyzer. The analyzer may be positioned before the feed stream 10 enters the heat exchanger 100. The feed stream 10 entering the analyzer may be a single phase.

While the feed stream 10 may be introduced into any section of the distillation tower 104, 204 regardless of the percentage of CO₂ in the feed stream 10, it is more efficient to introduce the feed stream 10 into the section of the distillation tower 104, 204 that will employ the best use of energy. For this reason, it is preferable to introduce the feed stream to the lower section 106 when the percentage of CO₂ in the feed stream is greater than any percentage about 20% or greater than 20% and to the middle controlled freeze zone section 108 when the percentage of CO₂ in the feed stream is any percentage less than about 20% or less than 20%.

The feed stream may be directly or indirectly fed to one of the sections 106, 108, 301. Thus, for the best use of energy it is best to introduce the feed stream into the distillation tower 104, 204 at the point in the distillation process of the distillation tower 104, 204 that matches the relevant percentage or content of CO₂ in the feed stream.

The feed stream 10 may enter a separator 208 (FIG. 5). The separator 208 separates a feed stream vapor portion from a feed stream liquid portion before the feed stream is introduced into the distillation tower 104, 204. The feed stream vapor portion may be fed to a different section or portion within a section of the distillation tower 104, 204 than the feed stream liquid portion. For example, the feed stream vapor portion may be fed to an upper controlled freeze zone section 39 of the middle controlled freeze zone section 108 and/or the feed stream liquid portion may be fed to a lower controlled freeze zone section 40 of the middle controlled freeze zone section 108 or to the lower section 106 of the distillation tower.

The lower section 106 is constructed and arranged to separate the feed stream 10 into an enriched contaminant bottom liquid stream (i.e., liquid stream) and a freezing zone vapor stream (i.e., vapor stream). The lower section 106 separates the feed stream at a temperature and pressure at which no solids form. The liquid stream may comprise a greater quantity of contaminants than of methane. The vapor stream may comprise a greater quantity of methane than of contaminants. In any case, the vapor stream is lighter than the liquid stream. As a result, the vapor stream rises from the lower section 106 and the liquid stream falls to the bottom of the lower section 106.

The lower section 106 may include and/or connect to equipment that separates the feed stream. The equipment may comprise any suitable equipment for separating methane from contaminants, such as one or more packed sections 181, or one or more distillation trays with perforations downcomers and weirs (FIGS. 1-4).

The equipment may include components that apply heat to the stream to form the vapor stream and the liquid stream. For example, the equipment may comprise a first reboiler 112 that applies heat to the stream. The first reboiler 112 may be located outside of the distillation tower 104, 204. The equipment may also comprise a second reboiler 172 that applies heat to the stream. The second reboiler 172 may be located outside of the distillation tower 104, 204. Line 117 may lead from the distillation tower to the second reboiler 172. Line 17 may lead from the second reboiler 172 to the distillation tower. Additional reboilers, set up similarly to the second reboiler described above, may also be used.

The first reboiler 112 may apply heat to the liquid stream that exits the lower section 106 through a liquid outlet 160 of the lower section 106. The liquid stream may travel from the liquid outlet 160 through line 28 to reach the first reboiler 112 (FIGS. 1-4). The amount of heat applied to the liquid stream by the first reboiler 112 can be increased to separate more methane from contaminants. The more heat applied by the reboiler 112 to the stream, the more methane separated from the liquid contaminants, though more contaminants will also be vaporized.

The first reboiler 112 may apply heat to the stream within the distillation tower 104, 204. Specifically, the heat applied by the first reboiler 112 warms up the lower section 106. This heat travels up the lower section 106 and supplies heat to warm solids entering a melt tray assembly 139 (FIGS. 1-4) of the middle controlled freeze zone section 108 so that the solids form a liquid and/or slurry mix.

The second reboiler 172 applies heat to the stream within the lower section 106. This heat is applied closer to the middle controlled freeze zone section 108 than the heat applied by the first reboiler 112. As a result, the heat applied by the second reboiler 172 reaches the middle controlled freeze zone section 108 faster than the heat applied by the first reboiler 112. The second reboiler 172 also helps with energy integration.

The equipment may include one or more chimney assemblies 135 (FIGS. 1-4). While falling to the bottom of the lower section 106, the liquid stream may encounter one or more of the chimney assemblies 135.

Each chimney assembly 135 includes a chimney tray 131 that collects the liquid stream within the lower section 106. The liquid stream that collects on the chimney tray 131 may be fed to the second reboiler 172. After the liquid stream is heated in the second reboiler 172, the stream may return to the middle controlled freeze zone section 106 to supply heat to the middle controlled freeze zone section 106 and/or the melt tray assembly 139. Unvaporized stream exiting the second reboiler 172 may be fed back to the distillation tower 104, 204 below the chimney tray 131. Vapor stream exiting the second reboiler 172 may be routed under or above the chimney tray 131 when the vapor stream enters the distillation tower 104, 204.

The chimney tray 131 may include one or more chimneys 137. The chimney 137 serves as a channel that the vapor stream in the lower section 106 traverses. The vapor stream travels through an opening in the chimney tray 131 at the bottom of the chimney 137 to the top of the chimney 137. The opening is closer to the bottom of the lower section 106 than it is to the bottom of the middle controlled freeze zone section 108. The top is closer to the bottom of the middle controlled freeze zone section 108 than it is to the bottom of the lower section 106.

Each chimney 137 has attached to it a chimney cap 133. The chimney cap 133 covers a chimney top opening 138 of the chimney 137. The chimney cap 133 prevents the liquid stream from entering the chimney 137. The vapor stream exits the chimney assembly 135 via the chimney top opening 138.

After falling to the bottom of the lower section 106, the liquid stream exits the distillation tower 104, 204 through the liquid outlet 160. The liquid outlet 160 is within the lower section 106 (FIGS. 1-4). The liquid outlet 160 may be located at the bottom of the lower section 106.

After exiting through the liquid outlet 160, the feed stream may travel via line 28 to the first reboiler 112. The feed stream may be heated by the first reboiler 112 and vapor may then re-enter the lower section 106 through line 30. Unvaporized liquid may continue out of the distillation process via line 24.

The systems may include an expander device 114 (FIGS. 1-4). After entering line 24, the heated liquid stream may be expanded in the expander device 114. The expander device 114 may be any suitable device, such as a valve. The valve 114 may be any suitable valve, such as a J-T valve.

The system may include a heat exchanger 116 (FIGS. 1-4). The liquid stream heated by the first reboiler 112 may be cooled or heated by the heat exchanger 116. The heat exchanger 116 may be a direct heat exchanger or an indirect heat exchanger. The heat exchanger 116 may comprise any suitable heat exchanger.

The vapor stream in the lower section 106 rises from the lower section 106 to the middle controlled freeze zone section 108. The middle controlled freeze zone section 108 is constructed and arranged to separate the feed stream 10 introduced into the middle controlled freeze zone section, or into the top of lower section 106, into a solid and a vapor stream. The middle controlled freeze zone section 108 forms the solid, 304 (FIG. 9). The solid may be comprised more of contaminants than of methane. The vapor stream (i.e., methane-enriched vapor stream) may comprise more methane than contaminants.

The middle controlled freeze zone section 108 includes a lower section 40 and an upper section 39 (FIG. 5). The lower section 40 is below the upper section 39. The lower section 40 directly abuts the upper section 39. The lower section 40 is primarily but not exclusively a heating section of the middle controlled freeze zone section 108. The upper section 39 is primarily but not exclusively a cooling section of the middle controlled freeze zone section 108. The temperature and pressure of the upper section 39 are chosen so that the solid can form in the middle controlled freeze zone section 108.

The middle controlled freeze zone section 108 may comprise a melt tray assembly 139 that is maintained in the middle controlled freeze zone section 108 (FIGS. 1-4). The melt tray assembly 139 is within the lower section 40 of the middle controlled freeze zone section 108. The melt tray assembly 139 is not within the upper section 39 of the middle controlled freeze zone section 108.

The melt tray assembly 139 is constructed and arranged to melt solids formed in the middle controlled freeze zone section 108. When the warm vapor stream rises from the lower section 106 to the middle controlled freeze zone section 108, the vapor stream immediately encounters the melt tray assembly 139 and supplies heat to melt the solids. The melt tray assembly 139 may comprise at least one of a melt tray 118, a bubble cap 132, a liquid 130 and heat mechanism(s) 134.

The melt tray 118 may collect a liquid and/or slurry mix. The melt tray 118 divides at least a portion of the middle controlled freeze zone section 108 from the lower section 106. The melt tray 118 is at the bottom 45 of the middle controlled freeze zone section 108.

One or more bubble caps 132 may act as a channel for the vapor stream rising from the lower section 106 to the middle controlled freeze zone section 108. The bubble cap 132 may provide a path for the vapor stream up the riser 140 and then down and around the riser 140 to the melt tray 118. The riser 140 is covered by a cap 141. The cap 141 prevents the liquid 130 from travelling into the riser and it also helps prevent solids from travelling into the riser 140. The vapor stream's traversal through the bubble cap 132 allows the vapor stream to transfer heat to the liquid 130 within the melt tray assembly 139.

One or more heat mechanisms 134 may further heat up the liquid 130 to facilitate melting of the solids into a liquid and/or slurry mix. The heat mechanism(s) 134 may be located anywhere within the melt tray assembly 139. For example, as shown in FIGS. 1-4, a heat mechanism 134 may be located around bubble caps 132. The heat mechanism 134 may be any suitable mechanism, such as a heat coil. The heat source of the heat mechanism 134 may be any suitable heat source.

The liquid 130 in the melt tray assembly is heated by the vapor stream. The liquid 130 may also be heated by the one or more heat mechanisms 134. The liquid 130 helps melt the solids formed in the middle controlled freeze zone section 108 into a liquid and/or slurry mix. Specifically, the heat transferred by the vapor stream heats up the liquid, thereby enabling the heat to melt the solids. The liquid 130 is at a level sufficient to melt the solids.

The middle controlled freeze zone section 108 may also comprise a spray assembly 129. The spray assembly 129 cools the vapor stream that rises from the lower section 40. The spray assembly 129 sprays liquid, which is cooler than the vapor stream, on the vapor stream to cool the vapor stream. The spray assembly 129 is within the upper section 39. The spray assembly 129 is not within the lower section 40. The spray assembly 129 is above the melt tray assembly 139. In other words, the melt tray assembly 139 is below the spray assembly 129.

The spray assembly 129 includes one or more spray nozzles 120 (FIGS. 1-4). Each spray nozzle 120 sprays liquid on the vapor stream. The spray assembly 129 may also include a spray pump 128 (FIGS. 1-4) that pumps the liquid. Instead of a spray pump 128, gravity may induce flow in the liquid.

The liquid sprayed by the spray assembly 129 contacts the vapor stream at a temperature and pressure at which solids form. Solids, containing mainly contaminants, form when the sprayed liquid contacts the vapor stream. The solids fall toward the melt tray assembly 139.

The temperature in the middle controlled freeze zone section 108 cools down as the vapor stream travels from the bottom of the middle controlled freeze zone section 108 to the top of the middle controlled freeze zone section 108. The methane in the vapor stream rises from the middle controlled freeze zone section 108 to the upper section 110. Some contaminants may remain in the methane and also rise. The contaminants in the vapor stream tend to condense or solidify with the colder temperatures and fall to the bottom of the middle controlled freeze zone section 108.

The solids form the liquid and/or slurry mix when in the liquid 130. The liquid and/or slurry mix flows from the middle controlled freeze zone section 108 to the lower distillation section 106. The liquid and/or slurry mix flows from the bottom of the middle controlled freeze zone section 108 to the top of the lower section 106 via a line 22 (FIGS. 1-4). The line 22 may be an exterior line. The line 22 may extend from the distillation tower 104, 204. The line 22 may extend from the middle controlled freeze zone section 108. The line may extend to the lower section 106. The line 22 may extend from an outer surface of the distillation tower 104, 204.

The middle controlled freeze zone section 108 may include a feed stream distribution mechanism 207 (FIGS. 5-8). The feed stream distribution mechanism 207 receives the feed stream introduced via inlet channel 12 to the middle controlled freeze zone section 108. The feed stream distribution mechanism 207 is constructed and arranged to uniformly distribute feed stream in the middle controlled freeze zone section 108. The feed stream distribution mechanism 207 is below the spray assembly 129. The feed stream distribution mechanism 207 is above the melt tray assembly 139. The feed stream distribution mechanism 207 is separate and distinct from the spray assembly 129 and the melt tray assembly 139.

The feed stream distribution mechanism 207 may comprise any mechanism that uniformly distributes feed stream introduced into the middle controlled freeze zone section 108, 303 (FIG. 9). For example, as shown in FIGS. 5-8, the feed stream distribution mechanism 207 may comprise a pipe header 209. Feed stream entering the feed stream distribution mechanism 207 may enter the feed stream distribution mechanism 207 through one (FIGS. 7-8) or more inlets 311.

The pipe header 209 includes orifices 206. The orifices 206 are closer to the melt tray assembly 139 than the spray assembly 129. The orifices 206 are angled downwards toward a controlled freeze zone section bottom 210 (FIG. 5) of the middle controlled freeze zone section 108. The orifices 206 may also be on a lower half 209 a of the pipe header 209 (FIG. 6). The orifices 206 may not be on an upper half 209 b of the pipe header 209 (FIG. 6). The lower half 209 a of the pipe header 209 is a lower half in the sense that it is closer to the bottom of the middle controlled freeze zone section 108 than the upper half 209 b. The orientation of the orifices 206 forces the feed stream 10 that exits the pipe header 209 through the orifices 206 to flow in a direction that promotes uniform distribution of the feed stream. The feed stream vapor portion flows downward when it first exits the orifices and then changes direction and flows upward in the middle controlled freeze zone section 108 toward the spray assembly 129. In other words, the feed stream vapor portion is directed toward the spray assembly 129 from the feed stream distribution mechanism 207. The feed stream vapor portion may be indirectly directed toward the spray assembly 129. The feed stream liquid portion flows downward when it first exits the orifices and continues to flow downward toward the melt tray assembly 139. In other words, the feed stream liquid portion is fed toward the melt tray assembly 139. The feed stream liquid portion may be directly fed toward the melt tray assembly 139.

To enhance the ability of the feed stream distribution mechanism 207 to uniformly distribute the feed stream introduced into the middle controlled freeze zone section 108, the feed stream distribution mechanism 207 may be shaped to promote uniform distribution.

The feed stream distribution mechanism 207 may comprise one of an H-shape and an X-shape (FIG. 7). The X-shaped feed stream distribution mechanism 207 of FIG. 7 includes a first pipe 211 and a second pipe 212. The first pipe 211 intersects the second pipe 212. The first pipe 211 extends from near to or a controlled freeze zone first side 213 of the controlled freeze zone wall 46 to near to or a controlled freeze zone second side 214 of the controlled freeze zone wall 46. As shown in FIG. 7, the first pipe 211 extends from the controlled freeze zone first side 213 to near to the controlled freeze zone second side 214. The first pipe 211 may connect to or include the inlet 311 to the feed stream distribution mechanism 207. The second pipe 212 extends from or near to a controlled freeze zone third side 215 of the controlled freeze zone wall 46 to near to or a controlled freeze zone fourth side 216 of the controlled freeze zone wall 46.

Other shapes of the feed stream distribution mechanism 207 are also possible. For example, as shown in FIG. 8 the feed stream distribution mechanism 207 may include a first pipe 211 and a second pipe 212. The first pipe 211 may intersect the second pipe 212. The feed stream distribution mechanism 207 may also include a third pipe 223 and a fourth pipe 224. The third pipe 223 may intersect the second pipe 212. The fourth pipe 224 may intersect the second pipe 212. The fourth pipe 224 may be parallel to the third pipe 223. The first pipe 211, third pipe 223, and/or fourth pipe 224 may extend from a controlled freeze zone first side 213 of the controlled freeze zone wall 46 to near to or a controlled freeze zone second side 214 of the controlled freeze zone wall 46. The first pipe 211 may connect to or include the inlet 311 to the feed stream distribution mechanism 207. The second pipe 212 may extend from the third pipe 223 to the fourth pipe 224.

The controlled freeze zone first side 213 is directly adjacent to the controlled freeze zone third side 215. The controlled freeze zone third side 215 is directly adjacent to the controlled freeze zone second side 214. The controlled freeze zone second side 214 is directly adjacent to the controlled freeze zone fourth side 216. The controlled freeze zone fourth side 216 is directly adjacent to the controlled freeze zone first side 213. If a pipe extends near to one of the sides 213, 214, 215, 216, the pipe may not connect to the side 213, 214, 215, 216. If a pipe extends from one of the sides 213, 214, 215, 216, the pipe connects to the side 213, 214, 215, 216. One or more of the pipes connect to or include the inlet 311 to the feed stream distribution mechanism 207. When a pipe connects to or includes the inlet 311 the inlet protrudes from the middle controlled freeze zone section 108 such that at least a portion of the inlet 311 is outside of the middle controlled freeze zone section 108.

The feed stream distribution mechanism 207 may also be a shape that minimizes the size and and/or cross-section, along a lateral axis 5,6-5,6 of the controlled freeze zone section 108, that the feed stream distribution mechanism 207 occupies in the middle controlled freeze zone section 108. The minimal size and/or cross-section of the feed stream distribution mechanism 207 and the relative warmth of the feed stream helps prevent undesired accumulation of the solid on the feed stream distribution mechanism 207.

The temperature of the feed stream that flows through the feed stream distribution mechanism 207 is warmer than the solid formed in the middle controlled freeze zone section 108. The feed stream is warmer because the feed stream introduced into the distillation tower 104, 204 is warmer than the solid formed in the middle controlled freeze zone section 108. The warmer temperature may prevent the feed stream from forming a solid inside of the feed stream distribution mechanism 207 and/or as the feed stream exits the feed stream distribution mechanism 207 and/or on an outer surface of the feed stream distribution mechanism 207.

As shown in FIGS. 1-2, the vapor stream that rises in the middle controlled freeze zone section 108 and does not form solids or otherwise fall to the bottom of the middle controlled freeze zone section 108, rises to the upper section 110. The upper section 110 operates at a temperature and pressure and contaminant concentration at which no solid forms. The upper section 110 is constructed and arranged to cool the vapor stream to separate the methane from the contaminants. Reflux in the upper section 110 cools the vapor stream. The reflux is introduced into the upper section 110 via line 18. Line 18 may extend to the upper section 110. Line 18 may extend from an outer surface of the distillation tower 104, 204.

After contacting the reflux in the upper section 110, the feed stream forms a vapor stream and a liquid stream. The vapor stream mainly comprises methane. The liquid stream comprises relatively more contaminants. The vapor stream rises in the upper section 110 and the liquid falls to a bottom of the upper section 110.

To facilitate separation of the methane from the contaminants when the stream contacts the reflux, the upper section 110 may include one or more mass transfer devices 176. Each mass transfer device 176 helps separate the methane from the contaminants. Each mass transfer device 176 may comprise any suitable separation device, such as a tray with perforations, or a section of random or structured packing to facilitate contact of the vapor and liquid phases.

After rising, the vapor stream may exit the distillation tower 104, 204 through line 14. The line 14 may emanate from an upper part of the upper section 110. The line 14 may extend from an outer surface of the upper section 110.

From line 14, the vapor stream may enter a condenser 122. The condenser 122 cools the vapor stream to form a cooled stream. The condenser 122 at least partially condenses the stream.

After exiting the condenser 122, the cooled stream may enter a separator 124. The separator 124 separates the vapor stream into liquid and vapor streams. The separator may be any suitable separator that can separate a stream into liquid and vapor streams, such as a reflux drum.

Once separated, the vapor stream may exit the separator 124 as sales product. The sales product may travel through line 16 for subsequent sale to a pipeline and/or condensation to be liquefied natural gas.

Once separated, the liquid stream may return to the upper section 110 through line 18 as the reflux. The reflux may travel to the upper section 110 via any suitable mechanism, such as a reflux pump 150 (FIGS. 1 and 3) or gravity (FIGS. 2 and 4).

The liquid stream (i.e., freezing zone liquid stream) that falls to the bottom of the upper section 110 collects at the bottom of the upper section 110. The liquid may collect on tray 183 (FIGS. 1 and 3) or at the bottommost portion of the upper section 110 (FIGS. 2 and 4). The collected liquid may exit the distillation tower 104, 204 through line 20 (FIGS. 1 and 3) or outlet 260 (FIGS. 2 and 4). The line 20 may emanate from the upper section 110. The line 20 may emanate from a bottom end of the upper section 110. The line 20 may extend from an outer surface of the upper section 110.

The line 20 and/or outlet 260 connect to a line 41. The line 41 leads to the spray assembly 129 in the middle controlled freeze zone section 108. The line 41 emanates from the holding vessel 126. The line 41 may extend to an outer surface of the middle controlled freeze zone section 110.

The line 20 and/or outlet 260 may directly or indirectly (FIGS. 1-4) connect to the line 41. When the line 20 and/or outlet 260 directly connect to the line 41, the liquid spray may be pumped to the spray nozzle(s) 120 via any suitable mechanism, such as the spray pump 128 or gravity. When the line 20 and/or outlet 260 indirectly connect to the line 41, the lines 20, 41 and/or outlet 260 and line 41 may directly connect to a holding vessel 126 (FIGS. 1 and 3). The holding vessel 126 may house at least some of the liquid spray before it is sprayed by the nozzle(s). The liquid spray may be pumped from the holding vessel 126 to the spray nozzle(s) 120 via any suitable mechanism, such as the spray pump 128 (FIGS. 1-2) or gravity. The holding vessel 126 may be needed when there is not a sufficient amount of liquid stream at the bottom of the upper section 110 to feed the spray nozzles 120.

It is important to note that the steps depicted in FIG. 7 are provided for illustrative purposes only and a particular step may not be required to perform the inventive methodology. The claims, and only the claims, define the inventive system and methodology.

Disclosed aspects may be used in hydrocarbon management activities. As used herein, “hydrocarbon management” or “managing hydrocarbons” includes hydrocarbon extraction, hydrocarbon production, hydrocarbon exploration, identifying potential hydrocarbon resources, identifying well locations, determining well injection and/or extraction rates, identifying reservoir connectivity, acquiring, disposing of and/or abandoning hydrocarbon resources, reviewing prior hydrocarbon management decisions, and any other hydrocarbon-related acts or activities. The term “hydrocarbon management” is also used for the injection or storage of hydrocarbons or CO₂, for example the sequestration of CO₂, such as reservoir evaluation, development planning, and reservoir management. The disclosed methodologies and techniques may be used to produce hydrocarbons in a feed stream extracted from, for example, a subsurface region. The feed stream extracted may be processed in the distillation tower 104, 204 and separated into hydrocarbons and contaminants. The separated hydrocarbons exit the middle controlled freeze zone section 108 or the upper section 110 of the distillation tower. Some or all of the hydrocarbons that exit are produced, 307 (FIG. 9). Hydrocarbon extraction may be conducted to remove the feed stream from for example, the subsurface region, which may be accomplished by drilling a well using oil well drilling equipment. The equipment and techniques used to drill a well and/or extract the hydrocarbons are well known by those skilled in the relevant art. Other hydrocarbon extraction activities and, more generally, other hydrocarbon management activities, may be performed according to known principles.

As utilized herein, the terms “approximately,” “about,” “substantially,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numeral ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described are considered to be within the scope of the disclosure.

It should be understood that numerous changes, modifications, and alternatives to the preceding disclosure can be made without departing from the scope of the disclosure. The preceding description, therefore, is not meant to limit the scope of the disclosure. Rather, the scope of the disclosure is to be determined only by the appended claims and their equivalents. It is also contemplated that structures and features in the present examples can be altered, rearranged, substituted, deleted, duplicated, combined, or added to each other.

The articles “the”, “a” and “an” are not necessarily limited to mean only one, but rather are inclusive and open ended so as to include, optionally, multiple such elements. 

What is claimed is:
 1. A distillation tower for separating a feed stream, the distillation tower comprising: a controlled freeze zone section having a controlled freeze zone upper section and a controlled freeze zone lower section below the controlled freeze zone upper section, wherein the controlled freeze zone section is constructed and arranged to form a solid from the feed stream, wherein the controlled freeze zone section comprises: (a) a spray assembly in the controlled freeze zone upper section; (b) a melt tray assembly in the controlled freeze zone lower section; and (c) a feed stream distribution mechanism between the spray assembly and the melt tray assembly, wherein the feed stream comprises a liquid portion and a vapor portion; a first inlet for directly introducing the vapor portion to the feed stream distribution mechanism wherein the feed stream distribution mechanism is constructed and arranged to uniformly distribute the vapor portion of the feed stream, in the controlled freeze zone section; wherein the feed stream distribution mechanism comprises a pipe header having a plurality of orifices that are distributed in pairs along a lower half of the pipe header, and wherein the upper half of the pipe header does not comprise orifices; wherein the feed stream distribution mechanism is configured such that the plurality of orifices are angled downwards towards the controlled freeze zone lower section and such that the pairs of orifices operate to direct the feed stream vapor portion downward when the feed stream vapor portion first exits the orifices and then direct the feed stream vapor portion upwards along the outer surface of the lower half of the pipe header towards the spray assembly; wherein the feed stream distribution mechanism operates to direct the vapor portion of the feed stream downward and toward the melt tray assembly; and a second inlet, at a different location from the first inlet, for directly introducing the liquid portion into the distillation column at the melt tray assembly.
 2. The distillation tower of claim 1, wherein the pipe header is one of H-shaped and X-shaped.
 3. The distillation tower of claim 1, wherein the pipe header includes a first pipe and a second pipe that intersects the first pipe.
 4. The distillation tower of claim 3, wherein the controlled freeze zone section includes a controlled freeze zone wall, wherein the first pipe extends from a first location of the controlled freeze zone wall to a second location of the controlled freeze zone wall, and wherein the second pipe extends from a third location of the controlled freeze zone wall to a fourth location of the controlled freeze zone wall.
 5. The distillation tower of claim 1, wherein the pipe header includes: a first pipe, a second pipe that intersects the first pipe, a third pipe that intersects the second pipe, and a fourth pipe that intersects the second pipe and is parallel to the third pipe.
 6. The distillation tower of claim 5, wherein the controlled freeze zone section includes a controlled freeze zone wall, and wherein the first pipe extends from the controlled freeze zone wall to the second pipe.
 7. The distillation tower of claim 1, wherein the distillation tower further comprises an inlet channel that extends from the controlled freeze zone section and transports the vapor portion of the feed stream into the controlled freeze zone section.
 8. The distillation tower of claim 7, wherein the feed stream comprises a hydrocarbon and a contaminant, and wherein the feed stream contains less than or equal to 20% contaminant when transported into the controlled freeze zone section from the inlet channel.
 9. The distillation tower of claim 1, wherein the feed stream distribution mechanism has a shape that minimizes the cross-section of the feed stream distribution mechanism along a lateral axis of the controlled freeze zone section.
 10. The distillation tower of claim 1, wherein the distribution of the vapor portion of the feed stream through the orifices of the feed stream distribution mechanism and around the outer surface of the pipe header acts to prevent the formation of solids on the outer surface of the feed stream distribution mechanism.
 11. A method of separating a feed stream in a distillation tower, the method comprising: directly introducing the feed stream into the distillation tower via a controlled freeze zone section of the distillation tower, wherein the feed stream comprises a vapor portion and a liquid portion, and wherein the vapor portion and the liquid portion are directly introduced into the distillation tower at different locations; operating the controlled freeze zone section at a temperature and pressure at which the liquid portion of the feed stream forms a solid in the controlled freeze zone section; uniformly distributing the vapor portion of the feed stream introduced into the controlled freeze zone section with a feed stream distribution mechanism that is below a spray assembly of the controlled freeze zone section and is above a melt tray assembly of the controlled freeze zone section; and forming a solid from the liquid portion of the feed stream in the controlled freeze zone section; wherein the feed stream distribution mechanism comprises a pipe header having a plurality of orifices that are distributed in pairs along a length of a lower half of the pipe header, and wherein the upper half of the pipe header does not comprise orifices; wherein the feed stream distribution mechanism is configured such that the plurality of orifices are angled downwards towards the controlled freeze zone lower section and such that the pairs of orifices operate to direct the vapor portion of the feed stream vapor portion downward and toward the melt tray assembly when the vapor portion of the feed stream first exits the orifices and then direct the vapor portion of the feed stream upwards along the outer surface of the lower half of the pipe header towards the spray assembly; introducing the liquid portion of the feed stream into the distillation tower at the melt tray assembly; and wherein the temperature of the feed stream that flows through the feed stream distribution mechanism is warmer than the solid that forms in the controlled freeze zone section.
 12. The method of claim 11, further comprising separating the vapor portion of the feed stream from the liquid portion of the feed stream before uniformly distributing the vapor portion of the feed stream.
 13. The method of claim 11, further comprising producing a hydrocarbon from the feed stream.
 14. The method of claim 11, wherein the temperature of the vapor portion of the feed stream within the feed stream distribution mechanism acts to prevent the formation of solids on the outer surface of the feed stream distribution mechanism.
 15. The method of claim 11, wherein the distribution of the vapor portion of the feed stream through the orifices of the feed stream distribution mechanism and around the outer surface of the pipe header acts to prevent the formation of solids on the outer surface of the feed stream distribution mechanism. 